• 051133 - ADDITIVE MANUFACTURING

The low-volume production of parts with highly complex geometries has long been regarded as an economically unfeasible task with traditional manufacturing processes. Such belief is now changing due to the introduction of Additive Manufacturing (AM) processes, often referred to with the collective term of 3D Printing. This course will provide an introduction to the AM processes and their applications, discussing their technical and business-oriented implications for designers, engineers, “makers” and other possible users of this advanced manufacturing technology.

After succesfully completing the course, the student will be able to:

Redesign x AM, having a correct landscape of all the principal AM processes (pros and cons), carry out a cost-and-value analysis of substituting current technologies with AM ones (Knowledge and understanding skills)

Develop new ideas and solutions in emerging industrial businesses. In fact, Additive manufacturing is one of the more active playground for new solutions, innovative ideas and start-ups. (Applying knowledge and making judgements)

Interact in a professional, responsible, effective and constructive way in a working environment. The project work will allow all the students to interact in a multi-disciplinary environment. In fact the project team will mix students in management, mechanical, design, automation and physics engineering (Team-working and communication abilities).

Introduction. Layer-by-layer principle. Benefits and limitation of AM. Historical development of AM technology. Generalized AM process chain. Materials and industrial applications: rapid prototyping, rapid tooling, direct digital manufacturing. Process selection, market availability and trends, business opportunities.

AM technology: Polymers. Description and modeling of the main AM processes for polymers. Machines, software issues, post-processing, design for.

AM technology: Metals. Description and modeling of the main AM processes for metals. Machines, software issues, post-processing, design for.

AM product verification. The need for precision metrology.Dimensional and geometrical metrology for AM: limits of tactile and optical measuring systems; volume based measuring systems: 3D X-ray computed tomography. Surface topography measurement (tactile, optical, other, analysis methods).

AM process monitoring. The need for precision processing. In-line monitoring for AM: process variables measurement, monitoring approaches, sensor and data fusion.

 Course organization

The course is organised into lectures, discussion of case studies, testimonials from industry, in-class exercises, and laboratory activities. Laboratory activities will be held at AddMe.Lab of the Mechanical Engineering Department and allow students to develop hands-on knowledge on specific AM problems. 

No specific pre-existing know-how is required. 

Grading will be based on an oral examination. During the oral exam, the students will be asked to show the acquired knowledge on AM processes, techniques and methods and and their skills to identify current AM trends, the existing technologies and key methodologies (Knowledge and understanding and Applying Knowledge and understanding abilities)